Deck system and method of installing

ABSTRACT

A deck system method of installing the deck system. The deck system includes a wooden-deck assembly and a deck-cover assembly and a method installing the deck system with a stone or tile top surface. The deck-cover assembly is applied to the wooden-deck assembly or another existing deck assembly. The deck-cover assembly includes a waterproof membrane and a second deck-top having the stone material. The stone tiles are maintained at a consistent spacing through the use of permanent spacers when not adhered to the deck surface. The deck system provides a durable and water-resistant stone deck.

BACKGROUND OF THE INVENTION

This application claims benefit to under 35 USC 119 to Canada National Application No. 3,028,082 filed on Dec. 19, 2018 the disclosure of which is incorporated herein by reference in its entirety. The following includes information that may be useful in understanding the present disclosure. It is not an admission that any of the information provided herein is prior art nor material to the presently described or claimed inventions, nor that any publication or document that is specifically or implicitly referenced is prior art.

TECHNICAL FIELD

The present invention relates generally to the field of construction and landscaping of existing art and more specifically relates to decking construction.

RELATED ART

In architecture, a deck is a flat surface capable of supporting weight, similar to a floor, but typically constructed outdoors, often elevated from the ground, and usually connected to a building. Residential decks may contain spaces for cooking, dining and seating. Decks are traditionally made from wood, treated lumber, composite lumber, composite material, and Aluminum. However, even with chemical treatments, traditional wood decking is not durable in an outdoor environment. A suitable solution is desired.

Canadian Pat. No. CA2768393 to Michael Dombowsky relates to a method for manufacturing and installing a textured cementitious tile flooring product. The described method for manufacturing and installing a textured cementitious tile flooring product includes method for manufacturing and installing a textured cementitious tile flooring product, wherein sodium bicarbonate is used to texture the tile surface and a polyurethane caulking material provides flexible joints between tiles.

SUMMARY OF THE INVENTION

In view of the foregoing disadvantages inherent in the known construction and landscaping art, the present disclosure provides a novel deck system and method of installing. The general purpose of the present disclosure, which will be described subsequently in greater detail, is to provide a simple stone covered wooden deck which is waterproof, long-lasting, cost-effective and durable.

A deck system is disclosed herein. The deck system includes a wooden deck assembly and a deck-cover assembly. The wooden deck assembly includes at least one post for securement into a ground surface, at least one joist including a horizontal joist-length relative to the ground surface, at least one beam joining the at least one post and the at least one joist, and a first deck-top having a first horizontal deck-length relative to the ground surface and laying atop the horizontal joist-length, and a first vertical deck-length relative to the ground surface and parallel to the vertical post-length and the vertical stud-length. The at least one post including a vertical post-length relative to the ground surface. The first deck-top is preferably constructed from a wooden material.

The deck-cover assembly includes a waterproof membrane including a horizontal membrane-length relative to the ground surface, a second deck-top including a second horizontal deck-length relative to the ground-surface, and a filler material. The second-deck top is constructed from a stone material. The system provides a long-lasting and cost-effective decking solution.

According to another embodiment, a method of installing an improved deck system is also disclosed herein. The method includes the steps of providing the improved deck system, the improved deck system including a wooden deck assembly having at least one post for securement into a ground surface; at least one joist including a horizontal joist-length relative to the ground surface; at least one beam joining the at least one post and the at least one joist; and a first deck-top having a first horizontal deck-length relative to the ground surface and laying atop the horizontal joist-length. The first deck-top being constructed from a wooden material, and a deck-cover assembly having a waterproof membrane including a horizontal membrane-length relative to the ground surface, and a vertical membrane-length relative to the ground-surface, a second deck-top including a second horizontal deck-length relative to the ground-surface, the second-deck top being constructed from a stone material, and a filler material; step two, installing the wooden deck assembly; step three, securing the waterproof membrane over the wooden deck assembly such that the horizontal membrane-length is seated atop the first horizontal deck-length, and the vertical membrane length is seated against the first vertical deck-length; step four seating the second deck-top over the waterproof membrane such that the second horizontal deck-length is parallel to the first horizontal deck-length, and the second vertical deck-length is parallel to the first vertical deck-length; and step five, using the filler material to seal gaps between the second deck-top and the waterproof membrane. The method may not include building the deck in certain embodiment, rather just covering the deck as an install.

For purposes of summarizing the invention, certain aspects, advantages, and novel features of the invention have been described herein. It is to be understood that not necessarily all such advantages may be achieved in accordance with any one particular embodiment of the invention. Thus, the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein. The features of the invention which are believed to be novel are particularly pointed out and distinctly claimed in the concluding portion of the specification. These and other features, aspects, and advantages of the present invention will become better understood with reference to the following drawings and detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The figures which accompany the written portion of this specification illustrate embodiments and methods of use for the present disclosure, a deck system, constructed and operative according to the teachings of the present disclosure.

FIG. 1 is a flow diagram illustrating a method of installing a deck system, according to an embodiment of the present disclosure.

FIG. 2 is a perspective view of the deck system of FIG. 1, according to an embodiment of the present disclosure.

FIG. 3 is a perspective view of the deck system of FIG. 1, according to an embodiment of the present disclosure.

FIG. 4 is a perspective view of the deck system of FIG. 1, according to an embodiment of the present disclosure.

FIG. 5 is a perspective view of the deck system of FIG. 1, according to an embodiment of the present disclosure.

FIGS. 6A and 6B are perspective views of a stone slab for the deck system of FIG. 1, according to an embodiment of the present disclosure.

FIG. 7 is a cut-away view of a water membrane joint of the deck system of FIG. 1, according to an embodiment of the present disclosure.

FIG. 8 is a perspective cut-away view of a wall edge according to an embodiment of the present disclosure.

The various embodiments of the present invention will hereinafter be described in conjunction with the appended drawings, wherein like designations denote like elements.

DETAILED DESCRIPTION

As discussed above, embodiments of the present disclosure relate to a construction and landscaping and more particularly to a method of installing a deck system as used to improve the installation of decks and other items using the method of installation and materials mentioned.

Generally, the present invention is a system to build a wood deck covered in stone, or similar, tile and the like, preferably with non-adhered stone or tile slabs in a geometric pattern. The system allows a simple wooden deck to be waterproof, last longer, and be covered with stone, all at the same time with a cost comparable to a composite deck alternative. A plurality of stone patterns may be used. All joists, beams, and posts of the system are preferably pressure treated or Douglas fir lumber. The deck surface may be surrounded with railings and include stairs if desired. Maximum rise and run of the stairs and railing requirements may be determined by local building codes. Permanent spacers are attached (like stickers) to the finished edge of the stone tile. The spacer is made of a material (rubber, plastic, or other suitable material) that can remain outdoors after placement. The spacers are placed offset on the edges such that they do not meet as the stone tiles are laid in patterns. Having a gap is important in creating an interlock between the stones when the stones are not attached to the surface, then having a consistent gap is ascetically pleasing as well as functional. The spacers achieve this and have the added advantage of still keeping the gap even if the gap filler fails in the future, allowing for easier replacement and or repair.

The spacers of the present invention allow an installer to quickly and efficiently lay tiles while keeping a consistent gap. The spacer will keep the gap consist during installation when the stone is not attached to the surface it is installed on. The product used to fill in the gaps after stone placement will not require the spacers to be removed prior to install. By installing the sticker onto the finished edge allows significant manufacturing advantages with current natural stone, and porcelain, and artificial stone manufacturing processes. The edge can be finished as normally manufactured and then the spacer added afterwards without significant cost. The spacers help to protect the stone edge during transportation and installation. Further, the spacers keep a consistent gap even if the stone is laid in an irregular pattern, therefore even when the corners of the stone are not aligned there is no change in installation production. This provides a significant advantage to installation whenever the stone is not being adhered to the underlaying deck or other installation surface. This also allows for installation of different sized tile without additional cost or labor. Further, this allows for more design and pattern options in the installation.

Use of bullnose (L-stones) with holes allows a thickened finished edge and hides the edge of the water proofing without needing to be attached with mortar or glue. The stone is made to be a good step for use on the stairs up to an elevated surface. The stone may overhang an edge of a deck, providing a bullnose to the deck, or step edge. These stones are not used when using the metal edge detailed. With the use of bullnose (L-stones) with holes, labor costs and installation time is saved. The holes may be manufactured in a factory. The holes may also be in a bracket attached to the stone, which allows the screw to be hidden from the finished view. The screw grips the stone while sitting flush and holding to the wood or other surface it is attached to. These stones hold the edge of all the stones on an elevated surface thereby allowing all the stones in the elevated surface to not require and adhesion to the surface. This securely holds all the stones without the need for glue or mortar making the tiled surface of an elevated surface quick and easy to install. The stones may be placed and secured directly onto a surface that may be difficult to adhere to.

Overlapping joints in the membrane lead to ridges that transfer to the stone tile when laid directly on the membrane. Therefore by installing the membrane flat, the stone tiles also sit flat when installed which eliminates the need for strips (or sleepers) to elevate the stone. This does not require any adhesion to, or of, the membrane. It allows for significant movement of the structure over time without failure of the water protection. Further, this allows for the structure and the tile to have different expansion/contraction rates without failure.

Referring now to the detail on how the membrane can be finished against the building provides 3 options. The first being that it can be extended up the wall without the need for any flashing. This provides for easy installation and eliminates a potential failure point in the connection of the membrane to a flashing. Two, it can be connected to a flashing in the case where option one is not practical or is not desirable. Lastly, it can be extended down between the building and the structure. This provides water protection the structure when a watertight connection to the building is not practical or is not desirable.

The detail at the deck edge provides three options. Firstly, it can be extended just over the facia providing simple installation and/or directing the water into an eaves. Secondly, it can extend down the side of the structure to provide additional water protection to the vertical side when desirable. Lastly, it can be run into the metal edge.

The metal edge is made to retain the stone tile on an elevated surface without any need for the tile to be adhered to the surface, while maintaining water protection. This design allows for a simple water protection, with easy installation. This design does not rely on the use of sealed connection. No penetrations through the water protection membrane will rely on sealant to maintain the water protection due to the overlapping design. This method also allows for easy installation without creating a ridge at the deck edge.

Allowing stone tile installation over a wood structure that retains flexibility means significant cost savings in the structure build as the structure does not have to be rigid. This allows the builder to use normal deck building methods that are already widely used in their community. This means lower costs, less unique expertise to install, more availability of the structure materials, more usability of existing structures, and savings on engineering costs since pre-approved deck building engineering can be utilized.

Referring now to tile installation, tile that is installed directly over the water protection can then be laid and finished the same way whether the tile is installed on the ground, or on concrete. Gravity laid stone tile allow the structure and the tile to remain flexible. The joints of tile have a consistent gap provided by the spacers, as mentioned previously. The joints are filled with a flexible jointing material. The present invention allows a user to lay stone directly on a surface with no space underneath the stone. Gaps between the stones may then be filled with a polymeric jointing sand with the gap distance maintained by the spacers during the process.

Referring now more specifically to the drawings by numerals of reference, there is shown in FIG. 1 a flow diagram illustrating a method of installing 100 for a deck system, according to an embodiment of the present disclosure. In particular, the installing an improved deck system 100 may include one or more components or features of the deck system 200 as described above. As illustrated in FIGS. 2-7, the method of use 100 may include the steps of: step one 101, providing the improved deck system 200, the improved deck system 200 including a wooden deck assembly having at least one post 106 for securement into a ground surface, the at least one post 106 including a vertical post-length 107 relative to the ground surface; at least one joist 108 including a horizontal joist-length 109 relative to the ground surface; at least one beam 111 joining the at least one post 106 and the at least one joist 108; at least one stud 112 including a vertical stud-length 113 relative to the ground-surface, the at least one stud 112 standing parallel to the at least one post 106; at least one brace, the at least one brace 114 including a diagonal-length 115 relative to the ground surface; and a first deck-top 116 having a first horizontal deck-length 117 relative to the ground surface and laying atop the horizontal joist-length 109, and a first vertical deck-length 118 relative to the ground surface and parallel to the vertical post-length 107 and the vertical stud-length 113, the first deck-top 116 being constructed from a wooden material (plywood), and a deck-cover assembly 120 having a waterproof membrane 121 including a horizontal membrane-length 122 relative to the ground surface, and a vertical membrane-length 123 relative to the ground-surface, a second deck-top 124 including a second horizontal deck-length 125 relative to the ground-surface, the second-deck top being constructed from a stone material, and a filler material 126; step two 102, installing the wooden deck assembly 110; step three 103, securing the waterproof membrane 121 over the wooden deck assembly 110 such that the horizontal membrane-length 122 is seated atop the first horizontal deck-length 117, and the vertical membrane length is seated against the first vertical deck-length; step four 104, seating the second deck-top 124 over the waterproof membrane 121 such that the second horizontal deck-length 125 is parallel to the first horizontal deck-length 117, and the second vertical deck-length is parallel to the first vertical deck-length; step five 105, using the filler material 126, preferably sand (polymeric sand), to seal gaps between the second deck-top 124 and the waterproof membrane 121. The waterproof membrane 121 is formed from a single sheet layer and is constructed from rubber, synthetic fiber, and/or foam. As shown in FIG. 7, the joint 141 between membranes 121, if needed, is grooved to allow the membranes 121 to overlap while maintain a level surface for placement of the slab pieces 133.

The method further includes flashing 131 overlapping the waterproof membrane 121. The flashing 131 is custom designed. The second deck-top 124 includes a bullnose overhanging 132. The bullnose stone portions are fastened using coated screws. Center stones are held in place by gravity and polymeric sand. Further, nailer boards and saddles may be secured using coated lag bolts. The second deck-top 124 further comprises a plurality of slab-pieces 133. The stone material is preferably natural stone or porcelain tile. Further, the deck system 200 may include a plurality of spacers 140 configured for placement between the plurality of slab-pieces 133. The spacers 140 and slab pieces 133 are shown in greater detail in FIGS. 6A and 6B. The spacers 140 may be stuck to the edges of the slab pieces and staggered so as to maintain spacing with overlap during installation, as non-adhered slab piece may otherwise be subject to movement and shifting of gaps. The spacers 140 are of particular use with natural stone or porcelain tile, where spacing nubs or marks cannot be engineered into the slab piece 133 as part of the manufacturing and shaping. The second deck-top 124 may include a decorative pattern 134 on a surface thereof. The first deck-top 116 comprises a plurality of tongue and groove pieces.

It should also be noted that the steps described in the method of use can be carried out in many different orders according to user preference. The use of “step of” should not be interpreted as “step for”, in the claims herein and is not intended to invoke the provisions of 35 U.S.C. § 112(f). It should also be noted that, under appropriate circumstances, considering such issues as design preference, user preferences, marketing preferences, cost, structural requirements, available materials, technological advances, etc., other methods for installing, are taught herein.

Referring now to FIGS. 2-7 showing various views of the deck system 200 according to an embodiment of the present disclosure. Here, the deck system 200 may be beneficial for use by a user to construct a stone covered deck. As illustrated, the deck system 200 may include a wooden deck assembly 110 and a deck-cover assembly 120. The wooden deck assembly 110 includes at least one post 106 for securement into a ground surface, at least one joist 108 including a horizontal joist-length 109 relative to the ground surface, at least one beam 111 joining the at least one post 106 and the at least one joist 108, at least one stud 112 including a vertical stud-length 113 relative to the ground-surface, at least one brace, and a first deck-top 116 having a first horizontal deck-length 117 relative to the ground surface and laying atop the horizontal joist-length 109, and a first vertical deck-length 118 relative to the ground surface and parallel to the vertical post-length 107 and the vertical stud-length 113. The at least one post 106 including a vertical post-length 107 relative to the ground surface. The at least one stud 112 standing parallel to the at least one post 106. The at least one brace 114 including a diagonal-length 115 relative to the ground surface. The first deck-top 116 being constructed preferably from a wooden material.

The deck-cover assembly 120 for installation over a wooden-deck assembly is provided. The wooden-deck assembly including a first deck-top 116 having a first horizontal deck-length 117 relative to a ground surface and a first vertical deck-length 118 relative to the ground surface. The deck-cover assembly 120 comprises a waterproof membrane 121 including a horizontal membrane-length 122 relative to the ground surface, and a vertical membrane-length 123 relative to the ground-surface. The horizontal membrane length configured for installation over the first horizontal deck-length 117, and the vertical membrane-length 123 being configured for installation over the first vertical deck-length.

The deck-cover assembly 120 further comprising a second deck-top 124 configured for installation over the waterproof membrane 121. The second deck-top 124 including a second horizontal deck-length 125 relative to the ground-surface, the second horizontal deck-length 125 being parallel to the first horizontal deck-length 117 when the second deck-top 124 is installed, the second deck-top 124 being constructed from a granite stone material; and a polymeric sand material for sealing gaps between the second deck-top 124 and the waterproof membrane 121. As shown in FIG. 5, The deck-cover assembly 120 further includes a custom designed flashing 131 configured to overlap the waterproof membrane 121. Providing a water protection surface to the wood will greatly prolong the life of the wooden structure. The water protection sits on the wooden, or other, surface flat, leaving no ridges. The waterproof membrane 121 can be gravity laid using no adhesive making installation quick and easy. In other embodiments, the waterproof membrane 121 may be attached to the first deck-top 116 via an adhesive. The adhesive may be jointing glue.

As shown in FIG. 8, an alternative metal edge formed from brackets 151 and 152 may be used to secure and retain the stone tile on an elevated surface (e.g. the edge of a raised patio deck) without the need to adhere the tile to the surface, while maintaining the water protection integrity of the deck. A hardie board 153 may be used to cover any vertical extending portions of waterproof membrane 121. The metal edge is preferably formed from the two brackets 151 and 152 for ease of installation and to eliminate the need to secure the tile or deck through the waterproof membrane 121, assisting in maintain integrity. Also, the upper bracket 151 eliminates and ridges along the edge of the tile and deck, preventing any water pooling or other potential water drainage issues. Additionally, only upper bracket 151 is visible, which means the lower bracket 152 may be left unfinished to reduce costs.

The embodiments of the invention described herein are exemplary and numerous modifications, variations and rearrangements can be readily envisioned to achieve substantially equivalent results, all of which are intended to be embraced within the spirit and scope of the invention. Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientist, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. 

What is claimed is new and desired to be protected by Letters Patent is set forth in the appended claims:
 1. A method of installing an improved deck system, the method comprising the steps of: providing the improved deck system, the improved deck system including: a wooden deck assembly having: at least one post for securement into a ground surface, the at least one post including a vertical post-length relative to the ground surface; at least one joist including a horizontal joist-length relative to the ground surface; at least one beam joining the at least one post and the at least one joist; a first deck-top having a first horizontal deck-length relative to the ground surface and laying atop the horizontal joist-length, and a first vertical deck-length relative to the ground surface and parallel to the vertical post-length, the first deck-top being constructed from a wooden material; and a deck-cover assembly having: a waterproof membrane including a horizontal membrane-length relative to the ground surface; a second deck-top including a second horizontal deck-length relative to the ground-surface, the second-deck top being constructed from a stone material; and a filler material; installing the wooden deck assembly; securing the waterproof membrane over the wooden deck assembly such that the horizontal membrane-length is seated atop the first horizontal deck-length, and the vertical membrane length is seated against the first vertical deck-length; seating the second deck-top over the waterproof membrane such that the second horizontal deck-length is parallel to the first horizontal deck-length, and the second vertical deck-length is parallel to the first vertical deck-length; and using the filler material to seal gaps between the second deck-top and the waterproof membrane.
 2. The method of claim 1, further comprising flashing overlapping the waterproof membrane.
 3. The method of claim 2, wherein the flashing is custom designed.
 4. The method of claim 1, wherein the second deck-top includes a bullnose overhanging.
 5. The method of claim 1, wherein the first deck-top comprises a plurality of tongue and groove pieces.
 6. The method of claim 1, wherein the wooden material is selected from one of: plywood, other wood and metal.
 7. The method of claim 1, wherein the second deck-top comprises a plurality of slab-pieces.
 8. The method of claim 1, further comprising a plurality of spacers configured for placement between the plurality of slab-pieces.
 9. The method of claim 1, wherein the stone material is selected from one or more of: granite, porcelain or another stone product.
 10. The method of claim 1, wherein the filler material is a sand material.
 11. The method of claim 10, wherein the sand material is polymeric sand.
 12. The method of claim 1, wherein the waterproof membrane is formed from a single sheet layer.
 13. The method of claim 1, wherein the waterproof membrane is constructed from rubber.
 14. The method of claim 1, wherein the waterproof membrane is constructed from synthetic fiber.
 15. The method of claim 1, wherein the waterproof membrane is constructed from foam.
 16. The method of claim 1, wherein the waterproof membrane is attached to the first deck-top via an adhesive.
 17. The method of claim 1, wherein the deck is secured to an elevated surface by an upper bracket secured to the surface and a lower bracket secured to the deck, the upper and lower bracket engaged with each other to form a waterproof connection.
 18. A stone slab piece for use in a deck surface comprising: a stone slab formed from natural stone, porcelain or artificial stone, the stone slab having a plurality of finished edges; and a plurality of spacers, with at least one spacer adhered to each finished edge so as to not overlap with spacers on adjacent slabs and maintain a consistent gap space between adjacent stone slabs during and after installation, wherein the spacers remain in place after installation of the stone slab piece and any related filler material.
 19. A deck-cover assembly for installation over a wooden-deck assembly, the wooden-deck assembly including a first deck-top having a first horizontal deck-length relative to a ground surface and a first vertical deck-length relative to the ground surface, the deck-cover assembly comprising: a waterproof membrane including a horizontal membrane-length relative to the ground surface, the horizontal membrane length configured for installation over the first horizontal deck-length; a second deck-top configured for installation over the waterproof membrane, the second deck-top including a second horizontal deck-length relative to the ground-surface, the second horizontal deck-length being parallel to the first horizontal deck-length when the second deck-top is installed, the second deck-top including a plurality of slab-pieces, the plurality of slab-pieces being non-adhered to the waterproof membrane and first deck top; a plurality of spacers permanently secured to edges of the slab piece and configured for placement in gaps between the plurality of slab-pieces to maintain spacing between slab pieces during installation; and a polymeric sand material for filling the gaps between the slab pieces.
 20. The deck cover assembly of clam 18, wherein the slab pieces are formed from one of more of: natural stone, porcelain, and engineered stone. 